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Cameras key to clean lines

Lining up panels and ensuring good fit and finish used to be a semi-manual job, accomplished by eye. Now Seat is using ‘photogrammetry’, or cameras, to measure placement to tenths of a millimetre across millions of data points.

Seat says photogrammetry is a process pioneering new levels of efficiency in measurement on the production line.

Sets of parts are randomly selected from the assembly line to be thoroughly checked during each production shift. AGVs (automated robots) transport these components to the measuring facilities. There the machines, equipped with cameras, begin the work to ensure that all vehicles leaving the production line have the correct dimensions almost wherever they can be measured. If any deviations are detected, these can then be quickly addressed.

Pedro Vallejo, head of measurement technology and meisterbock at Seat, explained: “Photogrammetry is a non-contact optical measurement technology that enables us to capture millions of points of an object through photos, marking the depth and thickness of each space.

“We’re the first manufacturer to roll out large scale, continuous non-contact, automated measurement. We’ve managed to ensure that a car coming off the line has the same level throughout the life of the series, like a perfect prototype.”

The process involves taking between 200 and 300 photos per assembly, and 1000 of the entire body, measuring the equivalent of seven million points per assembly and up to 98 million of an entire chassis.

The optical technology has saved up to 90 percent of the measuring time of the conventional process. It allows 9000 photos and up to 210 million points to be analysed each day.

Head of internal parts measurement at Seat, Paco Triguero, explained: “This has profoundly transformed the way we’ve been working for the last 20 or 30 years. We’ve trained workers in more highly qualified techniques, and exponentially increased the information we obtain so that the customer receives the best possible car.”

This technique is currently being applied on the assembly line of the Seat Leon and the Cupra Formentor.

“We’re storing all this data so that a machine learning algorithm can examine the frequency of any deviations,” says Pedro. “Now we’re able to locate them and react, but later on, a programme will act proactively. It will analyse how often deviations are repeated and make predictions to recalibrate the machine that produced the deviation.”

Seat is a member of the Volkswagen Group and is the only company that designs, develops, manufactures, and markets cars in Spain.

Actually, it’s a SsangYong

Devotees of New Zealand’s favourite pickups might need to think again. In the UK, SsangYong’s Musso has been voted ‘Best Pickturbodiesel engine make it easy to drive, and it can return over up’ in Diesel Car magazine’s Car of the Year 2021 Top 50 Awards for the third consecutive year.

The go-anywhere SsangYong Musso has already been voted to have the ‘Best Payload’ by What Car? magazine, and ‘Best Value’ and ‘Best Individual Model’ by 4x4 magazine, this year alone. Commentators have been swayed by the Musso’s combination of build quality, space, refinement, comfort, excellent warranty, and value for money.

Diesel Car’s journalist judging panel remarked: “The Musso is a highly capable pick-up, with a towing capacity of 3500kg and an impressive load bed.’’ They noted its low price in EX trim and its seven-year/150,000-mile warranty. “An accomplished chassis and 2.2-litre 178bhp 30mpg on a longer run. Clever features like rear cross traffic alerts also take some of the stress out of driving a pick-up in town, while three rear seats and a power socket in the load bed are handy too.” Kevin Griffin, managing director of SsangYong Motors UK, said: “We’re delighted to win the “Best Pick-Up” in Diesel Car magazine’s Car of the Year 2021 Top 50 Awards for three years running. Musso is the pick-up market’s best kept secret but things are about to change. It disrupts the pick-up market and rightly so — it’s a tough, strong, valuefor-money 4x4. Watch this space for the new, even better Musso launching this summer.”

Musso shares its body-on-frame construction with the new Rexton, which has also won multiple awards. SsangYong cars are manufactured in South Korea by SsangYong Motor, which is 75 percent owned by the Indian engineering conglomerate Mahindra & Mahindra.

Land Rover experiments with hydrogen engine

Jaguar Land Rover is developing a prototype hydrogen fuel cell electric vehicle (FCEV) for the new Land Rover Defender. Testing is due to begin this year.

The FCEV concept is part of Jaguar Land Rover’s drive to zero tailpipe emissions by 2036, and net zero carbon emissions across its supply chain, products, and operations by 2039.

The company sees FCEVs, which generate electricity from hydrogen to power an electric motor, as complementary to battery electric vehicles (BEVs). Hydrogen-powered FCEVs provide high-energy density and rapid refuelling, and minimal loss of range in low temperatures, making the technology ideal for larger, longerrange vehicles, or those operated in hot or cold environments.

Since 2018, the global number of FCEVs on the road has nearly doubled while hydrogen refuelling stations have increased by more than 20 percent. Forecasts predict hydrogen-powered FCEV deployment could top 10 million by 2030, with 10,000 refuelling stations worldwide.

Jaguar Land Rover’s engineering project, known as Project Zeus, aims to understand how a hydrogen powertrain can be optimised to deliver the performance and capability expected by customers — from range to refuelling, and towing to off-road ability.

The zero tailpipe emission prototype New Defender FCEV will begin testing towards the end of 2021.

Jaguar Land Rover has teamed up with Delta Motorsport, AVL, Marelli Automotive Systems, and the UK Battery Industrialisation Centre (UKBIC) to develop the prototype FCEV. “We know hydrogen has a role to play in the future powertrain mix across the whole transport industry, and alongside battery electric vehicles,” says Land Rover’s head of hydrogen and fuel cells, Ralph Clague. “It offers another zero tailpipe emission solution for Jaguar Land Rover’s world class line-up of vehicles. The project will help us prepare for the next generation of zero tailpipe emissions vehicles.”

All new Jaguar and Land Rover vehicle models offer the option of electrification.

A 230-mile range Zoe EV goes 475.4 miles

The Renault Zoe electric vehicle set a new ‘ hypermiling’ record of 475.4 miles after its team drove the all-electric supermini for more than 24 hours at the Thruxton race circuit in England.

The original record of 351 miles for the Zoe was set in France in 2018 on the Paris Périphérique, but the Mission Motorsport team, consisting of Royal British Legion veteran beneficiaries, military spouses, and a hypermiling expert, took the record on 10 June after an excellent display of deft driving on the UK’s fastest racetrack. Using its endurance motorsport experience, the team managed to achieve 9.14 miles per kilowatt hour, while averaging a remarkably restrained optimum speed of 19mph. Mission Motorsport is the Forces’ Motorsport Charity for those affected by military operations.

Two Renault Zoes were used for the record attempt, both of which were supplied by Hendy Renault. Both were standard, but one was running on Enso range extending tyres. With its original OEM tyres, the first Renault Zoe achieved 424.7 miles on a single charge to smash the existing record. It set off at 9.40am on Wednesday, 9 June, finally coasting to a stop at 11.45pm on Thursday, 10 June, having been driven for more than 22 hours.

However, the identical Renault Zoe, fitted with Enso’s proprietry EV tyres, went further still, achieving 475.4 miles. It started at the same time, but finished at 2.57pm the next day, after lapping Thruxton circuit in excess of 25 hours.

The feat betters the official WLTP range of the Renault Zoe by 230 miles, which has a recognised range of 245 miles on a single charge. Its standard specification has a 52kW battery being able to be charged to 80 percent in just 80 minutes.

Mission Motorsport CEO James Cameron was thrilled with the result: “The Zoe was a perfect choice for us — but to cover such an extraordinary distance frankly blew us away. It was important to set a record with an absolutely standard car, and we’ve all been charmed and astonished by the little Renault’s character and tenacity.”

Congratulating the charity on its record run, Tom Barker, Renault UK’s electrification manager, added: “Everyone at Renault UK sends a huge well done to them. Not only is it testament to how far it’s possible to go on a single charge in a Zoe, even taking into consideration the optimum conditions and low speed, but it’s a great illustration of just how comfortable and usable it is, too. There’s no doubt this was pretty extreme, but it’s further evidence that the Renault Zoe really does go the extra mile.”

The Renault Zoe E-Tech is the best-selling electric car in Europe. All new Zoe models come with a five-year/100,000-mile warranty, plus an eightyear/100,000-mile battery warranty.

Europe enters the battle of the batteries

Volkswagen has just upped its investment in Northvolt AB, a new battery-making plant in Skellefteå, northern Sweden, to help fund its planned expansion from a promise of 40GWh in batteries to 60GWh.

Volswagen has added US$620million (about NZ$900million) in Northvolt’s latest round of fundraising to maintain a 20 percent share. That’s on top of its initial investment of €900million (NZ$1528million) in Northvolt in June 2019.

In its first phase Northvolt aims to make enough batteries to power almost 300,000 electric vehicles a year but that could increase to a million. Its latest funding round raised an additional US$2.75bn (NZ$3.94bn) to fund its expansion.

The company has already received a US$14bn (NZ$20bn) order from Volkswagen to produce its batteries for the next decade, and has plans for a long-term partnership with Swedish truck and bus maker Scania. Production of cells in Skellefteå is due to start in 2023.

VW board member Arno Antlitz said: “With this investment, we are strengthening our strategic partnership with Northvolt as a supplier of sustainable battery cells which are produced using renewable energy and are comprehensively recyclable.”

TOTALLY NEW INDUSTRY

Northvolt was co-founded by two former Tesla executives. It is hoping to provide a quarter of Europe’s electric batteries as demand for electric vehicles surges amidst the global race to cut carbon emissions.

According to a forecast by investment bank UBS, by 2030 40 percent of all new cars sold will be electric, rising to almost 100 percent of the new car market by 2040.

Plant manager Fredrik Hedlund said: “We are building a totally new industry that hasn’t really existed, especially in Europe, at this scale. A lot of people think that this is the coolest project in Europe right now.”

Volkswagen’s Thomas Schmall, group board member for technology and CEO of Volkswagen group components, says batteries are one of the key success factors in VW’s electric offensive. “In the major area of green battery cells, we are assuming a pioneering role in Germany and Europe together.”

HOMEGROWN AND GREEN

The company is no doubt hoping it will help put distance on the ‘diesel-gate’ scandal involving the software faking of its previous generation of cars’ emissions performance. It will also see huge value in developing homegrown European tech, given the criticism of the carbon footprint of the transport miles involved in importing batteries from Asia which are generally produced using coal-fired power generation.

But the Europeans are playing catch-up and the competition from Asian battery makers is fierce. Several of them, including LG Chem, have already set up their own gigafactories in the EU. LG’s is in Poland, and Samsung SDI and SK Innovation have built factories in Hungary. They have the knowhow, the market, and deep pockets.

It is likely European makers will need practical support from national and regional governments as well as investors to thrive.

Northvolt is aiming to distinguish itself by making ‘the world’s greenest battery’, by ensuring its production techniques are as climate-friendly as its product.

VIRTUOUS CIRCLE

Hydroelectric power from the Skellefte River was one of the main attractions to siting the plant there, fuelling the battery-making process on the site which involves mixing lithium, cobalt, and other metals, and drying out active material in rows of industrial ovens. Local access to raw materials and plans for an on-site battery recycling plant will also keep down the plant’s own carbon footprint. Clearly, in the future — and in stark contrast with traditional fuels which have to be dug out of the ground for a single use — a major source of new batteries will be old batteries.

Norwegian energy company Freyr is planning a gigafactory fuelled by wind and hydro energy in Mo i Rana, a remote coastal town close to one of the country’s most popular ski resorts. Daimler and BMZ have already set up energy-efficient gigafactories in Germany. French start-up Verkor is planning a facility north of Toulouse. The UK is also planning to set up its own gigafactory by late 2023.

Volkswagen also has another gigafactory in Salzgitter that will produce standard cells from 2025. It is also expected to reach an annual production volume of up to 40GWh and will also use electric power from renewable energy sources.

Volkswagen expects to commission six cell factories in Europe by 2030 together with its partners with a view to safeguarding the ramp-up of electric vehicle production. After Skellefteå and Salzgitter, possible locations and partners for the next cell factories are already being considered.

Tucson takes top prize

The new Hyundai Tucson SUV was today named ‘Car of the Year 2021’ by the UK’s Diesel Car & Eco Car Magazine.

Commenting on the Tucson’s ‘Car of the Year 2021,’ and ‘Best Medium SUV’ accolades Diesel Car & Eco Car Magazine editor Ian Robertson said: “The Hyundai Tucson ushers in a new design language, taking it from ‘handsome’ to ‘trend-setting’. Its interior is a big step up, with great materials, a mature design, and an excellent infotainment system with an attractive instrument display. The hybrid model serves up plentiful performance and near-50mpg economy. We found the Tucson refined and capable, with excellent handling and plenty of traction. All in all, we not only think the Tucson perfectly fits the bill for buyers, but it also goes above and beyond the segment expectations, making it a very worthy winner.”

Hyundai Motor UK managing director Ashley Andrew said: “The all-new Tucson has already proven very popular with our customers. Of course, experts such as the professional road testers at Diesel Car & Eco Car Magazine can be even more demanding, so for the Tucson to receive the top award is extremely pleasing.”

The Hyundai Tucson SUV has Hybrid, Plug-in Hybrid, and Mild Hybrid models.

Making a start on ethical mining

Several companies have got together to create a ‘Responsible Lithium Partnership’ for natural resource management in Chile’s Salar de Atacama. This cross-industry partnership is funded at its inception by Volkswagen Group, BASF, Daimler AG, and Fairphone. The partnership intends to foster a dialogue among local stakeholders, build scientific knowledge, and seek solutions in a participatory manner.

The demand for lithium — a common mineral — for batteries is certain to grow. The world’s largest lithium reserves and large parts of the total production are located in the Salar de Atacama. The region’s ecosystem is fragile and there is a lack of consensus on the impact and risks of lithium mining and other economic activity in the region. Potential risks include water and brine table shifts.

The companies want to build a multistakeholder platform among all relevant actors in the Salar watershed including indigenous communities, government institutions, mining companies, and beyond.

The platform aims to develop a shared vision for the future of the Salar de Atacama watershed and develop a joint action plan to improve longterm integrated natural resource management. The Responsible Lithium Partnership shows responsible business conduct is not just about collaborating with business partners, but also relies on constructive engagement with governments and civil society.

Auto Channel looks forward to oil companies matching or bettering this initiative.

Polestar to make cars in the USA

Polestar, Volvo’s electric car co-brand will make its first all-electric SUV in the United States.

The forthcoming Polestar 3 will be manufactured alongside new Volvo vehicles at the Volvo Cars’ production centre in Ridgeville, South Carolina, for sale in the United States.

The move transforms Polestar into a global brand with industrial capacity in the two largest single markets for electric vehicles in the world — the US and China — alongside its headquarters in Europe.

The manufacturing announcement also underlines Polestar’s commitment to the rapidly expanding American retail market. Polestar will open around 25 retail ‘Spaces’ across the country in 2021 offering home test drives, free pick-up and delivery servicing, and a mobile service for consumers in places without Spaces.

Polestar was launched in 2017 by Volvo Cars and Geely Holding.

“Production in the USA reduces delivery times as well as the environmental impact associated with shipping vehicles around the world. It will even have a positive impact on the price of Polestar 3,” says Polestar chief operating officer Dennis Nobelius. “All of this makes the brand even more competitive in the critical American sales market.”

Production of Polestar 3 is expected to begin globally in 2022.